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I have a ragged out 200 that I'm trying to bring back to life. The rear brake pad pins are stuck. A metric hex seems to be the right size but it feel like it's going to strip if too much pressure is applied. Is it a hex or some size of a Torx bit. Are there metric Torx bits? Thanks

It probably WILL strip...cuz they're seized.
It's hex metric i believe.
Try some penetrating oil or maybe some heat and some small vise grip too.
Last resort, use an easy Out, Screw Extractors, or Left Hand Extractor or whatever they're called.

I had the same issue with the plug that covers the pin on my front caliper. See here http://www.kdxrider.net/forums/viewtopi ... highlight=

It's not the exact same issue but there might be some helpful hints in the thread.

The pin is definitely a metric hex. Don't recall the size but I think it is 5 mm. I would hit it for for several days with PB Blaster or equivalent and use some heat from a propane torch to loosen things up. If you can get a hex bit for what I call an impact driver, (smack it with a hammer and it puts torque on the bit as you are hitting it) then you should be able to get it freed up.

definitely get new ones...

scheckaet wrote:definitely get new ones...

+1
And I put a film of copper anti-seize on them when I put them back in. Same for the wretched pad bolt plugs.

Thanks for the suggestions. I used an impact driver on front brake pin plug and I'll try that on the rear pin if I can fit a hex to it. I've been applying liquid wrench to it for a few days. My fingers are crossed but I do have a extractor set if it strips. Looks like replacement pins are about $12 each!

If you buy EBC MXS pads the come with the pins. Other than that I have had the best luck with oem pins seems the zinc type coating stays better than the moose ones.

I have the tusk ones, I like the fact you use an open wrench and not a allen hex.
http://www.rockymountainatvmc.com/viewL ... vType=type

Good impact driver will help. So will careful heat.